Controlled activity pyrolysis catalysts

Abstract

A catalyst system is disclosed for catalytic pyrolysis of a solid biomass material. The system comprises an oxide, silicate or carbonate of a metal or a metalloid. The specific combined meso and macro surface area of the system is in the range of from 1 m 2 /g to 100 m 2 /g. When used in a catalytic process the system provides a high oil yield and a low coke yield. The liquid has a relatively low oxygen content.

1 . A catalytic system for use in catalytic pyrolysis of solid biomass material, said catalytic system comprising at least one metal oxide or metalloid oxide and having a specific combined meso and macro surface area in the range of from 1 m 2 /g to 100 m 2 /g. 
     
     
         2 . The catalytic system of  claim 1  having a specific combined meso and macro surface area in the range of from 2 m 2 /g to 60 m 2 g. 
     
     
         3 . The catalytic system of  claim 1  having a specific combined meso and macro surface area in the range of from 3 to 40 m 2 g. 
     
     
         4 . The catalytic system of  claim 1  comprising at least one component obtained by calcining a catalyst precursor at a temperature of at least 600° C. 
     
     
         5 . The catalytic system of  claim 4  comprising at least one component obtained by calcining a catalyst precursor at a temperature of at least 800° C. 
     
     
         6 . The catalytic system of  claim 4  comprising at least one component obtained by calcining a catalyst precursor at a temperature of at least 900° C. 
     
     
         7 . The catalytic system of  claim 4  comprising at least one component obtained by calcining a catalyst precursor at a temperature of at least 1000° C. 
     
     
         8 . The catalyst system of  claim 4  wherein the catalyst precursor comprises a phyllosilicate mineral. 
     
     
         9 . The catalyst system of  claim 8  wherein the phyllosilicate mineral is a clay mineral. 
     
     
         10 . The catalyst system of  claim 9  wherein the clay mineral comprises kaolinite. 
     
     
         11 . The catalyst system of  claim 10  wherein the clay mineral comprises kaolin that has been exposed to temperatures of at least 500° C. 
     
     
         12 . The catalyst system of  claim 10  wherein the clay mineral comprises bentonite that has been exposed to temperatures of at least 500° C. 
     
     
         13 . The catalyst system of  claim 10  wherein the clay mineral comprises smectite. 
     
     
         14 . The catalyst system of  claim 4  wherein the catalyst precursor is hydrotalcite or a hydrotalcite-like material. 
     
     
         15 . The catalyst system of  claim 4  wherein the catalyst precursor is an aluminosilicate. 
     
     
         16 . The catalyst system of  claim 15  wherein the aluminosilicate is a zeolite Y, ion exchange Y zeolite, and/or is terminally treated, or dealuminated. 
     
     
         17 . The catalyst system of  claim 16  wherein the zeolite is zeolite ZSM-5. 
     
     
         18 . The catalytic system of  claim 1  comprising at least one component obtained by steam-deactivating a catalyst precursor at a temperature of at least 400° C. 
     
     
         19 . The catalytic system of  claim 18  comprising at least one component obtained by steam-deactivating a catalyst precursor at a temperature of at least 600° C. 
     
     
         20 . The catalytic system of  claim 18  comprising at least one component obtained by steam-deactivating a catalyst precursor at a temperature of at least 800° C. 
     
     
         21 . The catalytic system of  claim 1  wherein the catalytic system comprises a metal selected from the group consisting of: 1) the earth alkaline earth metals selected from, in particular calcium, barium, magnesium and iron; 2) the transition metals selected from iron, manganese, copper and zinc; and 3) rare earth metals selected from cerium and lanthanum. 
     
     
         22 . The catalyst system of  claim 1  comprising alumina. 
     
     
         23 . The catalyst system of  claim 22  wherein said alumina has been exposed to temperatures of at least 500° C. 
     
     
         24 . The catalyst system of  claim 1  comprising silica. 
     
     
         25 . The catalyst system of  claim 1  comprising a mixed metal oxide. 
     
     
         26 . The catalyst system of  claim 1  in the form of microspheres. 
     
     
         27 . The catalyst system of  claim 26  wherein the microspheres have a mean particle diameter in the range of from 20 to 200 μm. 
     
     
         28 . The catalyst system of  claim 26  wherein the microspheres have a mean particle diameter in the range of from 40 to 100 μm. 
     
     
         29 . The catalyst system of  claim 1  further comprising a binder. 
     
     
         30 . A bio-oil produced from the catalytic pyrolysis of biomass in the presence of the catalyst system of  claim 1 . 
     
     
         31 . The process of  claim 30  wherein the yield of said bio-oil from said biomass is higher than the bio-oil yield resulting from use of catalyst systems having higher specific combined meso and macro surface area. 
     
     
         32 . The process of  claim 30  wherein the temperature of the catalytic pyrolysis reactor is at least 850° F. 
     
     
         33 . A bio-oil produced from the catalytic pyrolysis of biomass in the presence of the catalyst system of  claim 8 . 
     
     
         34 . A bio-oil produced from the catalytic pyrolysis of biomass in the presence of the catalyst system of  claim 16 . 
     
     
         35 . A bio-oil produced from the catalytic pyrolysis of biomass in the presence of the catalyst system of  claim 21 .